Materials and methods for improved intragastric balloon devices

ABSTRACT

Disclosed is a balloon of an intragastric device, comprising, in combination: a core of a first material and having an inner surface and an outer surface; and a coating of a second material on at least one of the inner surface of the core and the outer surface of the core. Disclosed is a method, comprising, in combination: creating a core of a balloon by a core in a first material; dipping at least one of an inner surface of the core and an outer surface of the core in a second material, whereby a coating is formed on at least one of the inner surface of the core and the outer surface of the core. Also disclosed are products by processed disclosed herein. The first material may be of a more dimensional consistency than the second material, have a greater elasticity than the second material, or be primarily of polydimethylsiloxane. The second material may be of higher acid resistance than the first material, be less permeable than the first material, or be primarily of polydiphenylsiloxane.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. application Ser. No.13/577,618, filed Aug. 28, 2012, which is a national stage entry of PCTApplication No. PCT/US2011/024082, filed Feb. 8, 2011, which claimspriority under 35 U.S.C. §119(e) to U.S. Provisional Application No.61/302,465, filed Feb. 8, 2010, the disclosures of which areincorporated herein by reference in their entireties.

RELATED REFERENCES

This application incorporates by reference: U.S. Pat. Pub. No.2007/0100367, published May 3, 2007; U.S. Pat. Pub. No. 2007/0100368,published May 3, 2007; U.S. Pat. Pub. No. 2007/0100369, published May 3,2007; U.S. Pat. Pub. No. 2007/0149994, published Jun. 28, 2007; U.S.Pat. Pub. No. 2008/0243071, published Oct. 2, 2008; U.S. Pat. Pub. No.2008/0319471, published Dec. 25, 2008; U.S. Pat. Pub. No. 2005/0159769,published Jul. 21, 2005; U.S. Pat. Pub. No. 2009/0048624, published Feb.19, 2009; WIPO Pub. No. WO 2007/053556, published Oct. 5, 2007; WIPOPub. No. WO 2007/053707, published Oct. 5, 2007; WIPO Pub. No. WO2007/053706, published Oct. 5, 2007; and WIPO Pub. No. WO 2007/075810,published May 7, 2007; each as if fully set forth herein in itsentirety.

BACKGROUND

This disclosure relates to implantable, expandable gastric devices. Inparticular, this disclosure relates to improved structures of balloonsand methods of producing the same.

Many conventional implantable gastric devices have a balloon filled witha biocompatible fluid. Such gastric devices are generally inserted intothe stomach when the balloon is deflated and then inflated in vivo. Thegastric devices are often left in the stomach for an extended period oftime to treat severe obesity or other conditions. The gastric devicesare eventually removed after completing the treatment or for otherreasons by deflating the balloon, grasping the gastric device with anextraction tool, and extracting the gastric device via the esophagus andmouth. Conventional gastric devices are deflated by attempting topuncture the balloon and aspirate the biocompatible fluid through aneedle.

One challenge of conventional devices is that the balloon are generallyfairly large in a deflated state because of the limited elasticity andexpansion of the materials that can withstand the harsh environmentwithin the stomach rupture. Many existing balloons for intragastricdevices are made from polydiphenylsiloxane (PDPS), which resistsdegradation by acids, fungal growth and other microbial growth, but ithas limited expansion. As such, the cuffs of such a balloon must have afairly large diameter so that the balloon can be removed from a mandrelduring the manufacturing process.

Another challenge of conventional intragastric devices is the life spanof the balloon. For example, fungi or other microbes can grow into thematerial of the balloon and effectively decrease the wall thickness.This can weaken the balloon wall to the point that it ruptures under thepressure of the fluid in the balloon.

BRIEF DESCRIPTION OF THE DRAWINGS

Several embodiments of the present technology will become more apparentwith reference to the following description taken in conjunction withthe accompanying drawings wherein like reference numerals denote likeelements and in which:

FIG. 1 shows a perspective view of a balloon;

FIG. 2 shows a perspective view of an intragastric device;

FIG. 3 shows a side view of an intragastric device;

FIG. 4 shows a top view of an intragastric device;

FIG. 5 shows a sectional view of a balloon with a magnified view;

FIG. 6 shows a sectional view of a balloon with a magnified view; and

FIG. 7 shows a sectional view of a balloon with a magnified view.

DETAILED DESCRIPTION

Specific details of several embodiments of the present technology aredescribed below with reference to an intragastric device with compoundballoon. Although many of the embodiments are described below withrespect to a dual balloon intragastric device, other types of deviceswith only one balloon or more than two balloons may be within the scopeof the technology. Moreover, several other embodiments of the technologycan have different configurations, components, or procedures than thosedescribed in this section. A person of ordinary skill in the art,therefore, will accordingly understand that the technology may haveother embodiments with additional elements, or the technology may haveother embodiments without several of the features shown and describedbelow with reference to FIGS. 1-7.

Several embodiments of the technology are directed to a balloon of anintragastric device comprising, in combination, a substrate or core of afirst material that has having an inner surface and an outer surface,and a coating of a second material on at least one of the inner or outersurfaces. The substrate, for example, can be more elastic and/or havemore expansion than the coating, and the coating can be more resistantto fungal or other microbial growth than the substrate.

Additional embodiments of the technology are directed to a methodcomprising, in combination, forming a core or substrate of a firstmaterial into a balloon and covering at least one of an inner surfaceand/or outer surface of the substrate with a second material. The secondmaterial can be a coating that is sprayed, painted or applied by dippingthe substrate into the second material, to form a smoother surfacefinish, as compared to a surface finish of a molded core, having aroughness from about 0.1 to 0.7 micron. This further inhibits orotherwise impedes the formation of biofilm (e.g., candida) on the coatedsurface of the balloon. Also disclosed are products by processeddisclosed herein.

The first material may be of a more dimensionally stable or consistantthan the second material and/or have a greater elasticity than thesecond material. In one embodiment, the first material comprisespolydimethylsiloxane (PDMS). The second material may have a higherresistance to acid, be more resistant to fungal or other microbialactivity, and be less permeable than the first material. In oneembodiment, the second material comprises PDPS.

In the specific embodiment shown in FIG. 1, a balloon 30 can be one ofseveral expandable, space filling components. In several embodiments,and as shown in FIG. 2, the balloon 30 may be a component of anintragastric device 10. For example, as further shown in FIG. 2, theintragastric device 10 can have a shaft 20 and a plurality of theballoons 30 may be joined or otherwise carried by the shaft 20.

The balloon 30 may have many different geometries and shapes accordingto the specific anatomy in which the balloon 30 is implanted. As shownin FIGS. 1 and 3, the balloon 30 may have at least one cuff 40 forinterfacing with the shaft 20 (FIG. 2) such that the shaft 20 extendsthrough the balloon 30. The balloon 30 may be an open or closed balloon,and the balloon 30 may have an inner surface and outer surface.

According to several embodiments of the technology, the intragastricdevice 10 may be configured for use as an implantable device within agastric cavity. In many applications, the intragastric device 10 isimplanted for several months in the stomach or other gastric cavityhaving high concentrations of acids and microbes that can deterioratethe balloon 30. The durability and longevity of the intragastric device10 is accordingly defined, at least in part, by the ability of theballoon 30 to resist the harsh environment within the stomach. As such,the materials and manufacturing methods of the materials are keycontributors as to balloon integrity and longevity.

According to embodiments, the balloon 30 may comprise a combination oftwo different silicone-containing materials. Two examples of suchmaterials are PDMS and PDPS. PDMS may be represented as [SiO(CH₃)₂]_(n)or graphically as follows:

PDPS may be represented as [SiO(C₆H₅)₂]_(n) or graphically as follows:

According to several embodiments of the technology, at least one of PDMSand PDPS may form the substrate or core of at least a portion of theballoon 30. Other materials, structures, or compounds may be mixed orcross-linked with the based material.

According to several embodiments of the technology, a plasma etching orcoating may be provided to at least a portion of the balloon 30. Plasmaetching may involve a high-speed stream of glow discharge (plasma) of anappropriate gas mixture being shot (in pulses) at a sample. The plasmasource can be either charged (ions) or neutral (atoms and radicals).During the process, the plasma will generate volatile etch products atroom temperature from the chemical reactions between the elements of thematerial etched and the reactive species generated by the plasma. Theatoms of the shot element embed themselves at or just below the surfaceof the target, thus modifying the physical properties of the balloon 30.Etching may facilitate better adherence between layers of the balloon30.

According to several embodiments of the technology, various coatings(e.g., hydrophilic) may be applied to at least a portion of substrate orcore of the balloon 30. For example, a hydrophilic coating may beprovided where two surfaces of the balloon 30 resist flow of fluid therethrough.

The respective chemical structures of PDMS and PDPS have relativelydisparate characteristics, which may be summarized as follows:

Polydimethylsiloxane Polydiphenylsiloxane Manufacturing method: Molding,extrusion Dipping Curing: Heat Heat Consistency: More dimensional Lessdimensional (moldable) (dipping) Elasticity: Higher Lower TensileStrength: Lower Higher Acid resistance: Acceptable IncreasedPermeability: Higher LowerIn various applications and based on different aspects, each of PDMS andPDPS may be seen as providing certain advantages and disadvantages.

According to several embodiments of the technology, the dimensionalstability or consistency and elasticity of PDMS materials and PDMSblends enable the balloon 30 to be formed using molding and extrusionprocesses instead of a dipping process. In particular, molding processesinclude molding the PDMS material over a mandrel, and the higherelasticities of PDMS materials compared to PDPS materials reduce thestresses involved in removing the mandrel. For example, the balloon 30may be formed using a mandrel that has a larger diameter at a centralportion than at one or both ends (corresponding to cuffs 40). Forexample, the diameter at the middle of a mandrel may be up to 600%larger than at the end of the mandrel. The balloon 30 must sufficientlyelastic to remove the mandrel through the cuff 40 without damaging thecuff 40.

According to several embodiments of the technology, the expansion ratioof the balloon 30 from an uninflated state (i.e., before and duringimplant) to an inflated state (i.e, after implant) may be significant.For example, the balloon 30 may have an outer diameter of about 1.9″ inan uninflated state and about 4″ in an inflated state (over 200%expansion). By further example, the balloon 30 may have a volume ofabout 80 cc in an uninflated state and about 450 cc in an inflated state(over 500% expansion). These factors are well-served by PDMS materialsand PDMS blends. As such, PDMS and PDMS blends are well suited for thesubstrate or core of the balloon 30.

In accordance with several embodiments of the invention, the higher acidresistance and less permeability of PDPS materials and PDPS blends,compared to PDMS based materials, better limit the ingress or egress ofmaterials across the walls of the balloon 30 and support longevity ofthe balloon 30. Generally, PDPS, as compared to PDMS, is less able toprovide consistent wall thicknesses and is less capable of generatingmolding friendly features, but more capable of resisting acids andgrowth of fungi or bacteria.

In several specific embodiments of the technology, the balloon 30 has amultiple-material composition in which a plurality of disparatematerials and material blends may be provide in layers forming walls ofthe balloon 30. For example, a wall of the balloon 30 may have asubstrate or core with at least one coating on an inner or outer surfacethereof.

FIGS. 5 and 6 illustrate specific embodiments of the technology. In theembodiment shown in FIG. 5, the balloon can have a substrate or core 50and outer coating 60 a over an outer surface of the core 50. The outercoating 60 a may be provided, for example, by a dipping process aftercore 50 is formed. In the embodiment shown in FIG. 6, the balloon 30 canhave in inner coating 60 b over an inner surface of the core 50. Theinner coating 60 b may be provided, for example, by a dipping processafter core 50 is formed and the balloon inverted inside-out.

FIG. 7 illustrates another embodiment in which the balloon has thesubstrate or core 50, the outer coating 60 a over the outer surface ofthe core, and an inner coating 60 b over the inner surface of the core50. The outer coating 60 a and inner coating 60 b may be provided, forexample, by a dipping process after core 50 is formed.

In selected embodiments, the substrate or core 50 can comprise PDMS oranother material that is moldable and has a higher elasticity than PDPS.The inner and/or outer coatings 60 a-b can comprises PDPS or anothermaterial that is less permeable and more acid resistant than PDMS.According to several embodiments, the balloon 30 having a layered,multiple-material composition may benefit from the advantaged of eachmaterial while mitigating or minimizing the detriments of each.

The present technology is also directed to methods of making the balloon30 is disclosed. In one embodiment, the substrate or core 50 may bemolded of the first material, such as a liquid silicone rubber (LSR)grade material (e.g., such as PDMS). Those skilled in the art willrecognize various molding and extrusion processes that may facilitateformation of core 50. The molding process can include injecting PDMS ora PDMS blend into a mold such that the molded material surrounds amandrel or other form. After curing, the core 50 is removed from themold, mandrel, or other device, and then the second material may becoated onto the inner and/or outer surface of the core 50. For example,the core 50 may be dipped in the second material to form at least one ofthe outer coating 60 a and/or the inner coating 60 b. Other embodimentsof the method, the core 50 may be coated using other techniques, such asspraying, painting, coating, washing, etc. The second material can bePDPS or another suitable low-permeable, acid and fungal resistantmaterial.

The core 50 may compose a substantial portion of the total sum of theballoon 30 or at least the walls thereof. For example, the thickness ofcore 50 may be about 0.001 inch to about 1.0 inch. By further example,the thickness of core 50 may be about 0.024 inch to about 0.030 inch.The core 50 can have other thicknesses based on the needs andapplications of the desired product.

The outer coating 60 a or the inner coating 60 b may be a thin relativeto the thickness of core 50. For example, the outer coating 60 a or theinner coating 60 b may have a thickness of about 1% to about 99% of thethickness of core 50. By further example, the outer coating 60 a or theinner coating 60 b may have a thickness of about 10% to about 20% of thethickness of core 50. The inner and outer coating 60 a-b can have otherthicknesses based on the needs and applications of the desired product.It should be noted that outer coating 60 a or inner coating 60 bcomprising PDPS materials increase the stiffness of the balloon 30 andreduce elongation properties thereof.

In still additional embodiments of the technology, the core 50 and/orthe coating 60 can include anti-microbial or other additives to impartadditional therapeutic, durability, or other properties to the balloon30. For example, such additives can be distributed homogeneously in thecoating 60, or the additives can be a constituent of another coatingapplied directly to the core 50 or to the coating 60. When such anadditional coating is applied directly to the core 50, the coating 60can be applied onto the other coating. In several specific examples, theadditives can comprise salt or silver-based anti-microbial materialsthat inhibit the growth of microbes on and/or into the core 50.

The multi-layered construction of first and second materials of severalembodiments of the balloon may have a substantially consistent surfaceand retain elastic material properties, increased acid resistance, andlower permeability. For example, the first material of the core 50 canprovide good elasticity enable molding processes that provide acontrolled wall thickness, and the second material of the coating 60 canprovide good resistance to acid, fungus, bacteria and other microbes.The second material of the coating 60 can also have a low permeability.

Although the method and agent have been described in terms of what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the disclosure need not be limited to thedisclosed embodiments. It is intended to cover various modifications andsimilar arrangements included within the spirit and scope of the claims,the scope of which should be accorded the broadest interpretation so asto encompass all such modifications and similar structures. The presentdisclosure includes any and all embodiments of the following claims.

It should also be understood that a variety of changes may be madewithout departing from the essence of the invention. Such changes arealso implicitly included in the description. They still fall within thescope of this invention. It should be understood that this disclosure isintended to yield a patent covering numerous aspects of the inventionboth independently and as an overall system and in both method andapparatus modes.

Further, each of the various elements of the invention and claims mayalso be achieved in a variety of manners. This disclosure should beunderstood to encompass each such variation, be it a variation of anembodiment of any apparatus embodiment, a method or process embodiment,or even merely a variation of any element of these.

Particularly, it should be understood that as the disclosure relates toelements of the invention, the words for each element may be expressedby equivalent apparatus terms or method terms—even if only the functionor result is the same.

Such equivalent, broader, or even more generic terms should beconsidered to be encompassed in the description of each element oraction. Such terms can be substituted where desired to make explicit theimplicitly broad coverage to which this invention is entitled.

It should be understood that all actions may be expressed as a means fortaking that action or as an element which causes that action.

Similarly, each physical element disclosed should be understood toencompass a disclosure of the action which that physical elementfacilitates.

Any patents, publications, or other references mentioned in thisapplication for patent are hereby incorporated by reference. Inaddition, as to each term used it should be understood that unless itsutilization in this application is inconsistent with suchinterpretation, common dictionary definitions should be understood asincorporated for each term and all definitions, alternative terms, andsynonyms such as contained in at least one of a standard technicaldictionary recognized by artisans and the Random House Webster'sUnabridged Dictionary, latest edition are hereby incorporated byreference.

Finally, all referenced listed in the Information Disclosure Statementor other information statement filed with the application are herebyappended and hereby incorporated by reference; however, as to each ofthe above, to the extent that such information or statementsincorporated by reference might be considered inconsistent with thepatenting of this/these invention(s), such statements are expressly notto be considered as made by the applicant(s).

In this regard it should be understood that for practical reasons and soas to avoid adding potentially hundreds of claims, the applicant haspresented claims with initial dependencies only.

Support should be understood to exist to the degree required under newmatter laws—including but not limited to United States Patent Law 35 USC132 or other such laws—to permit the addition of any of the variousdependencies or other elements presented under one independent claim orconcept as dependencies or elements under any other independent claim orconcept.

To the extent that insubstantial substitutes are made, to the extentthat the applicant did not in fact draft any claim so as to literallyencompass any particular embodiment, and to the extent otherwiseapplicable, the applicant should not be understood to have in any wayintended to or actually relinquished such coverage as the applicantsimply may not have been able to anticipate all eventualities; oneskilled in the art, should not be reasonably expected to have drafted aclaim that would have literally encompassed such alternativeembodiments.

Further, the use of the transitional phrase “comprising” is used tomaintain the “open-end” claims herein, according to traditional claiminterpretation. Thus, unless the context requires otherwise, it shouldbe understood that the term “compromise” or variations such as“comprises” or “comprising”, are intended to imply the inclusion of astated element or step or group of elements or steps but not theexclusion of any other element or step or group of elements or steps.

Such terms should be interpreted in their most expansive forms so as toafford the applicant the broadest coverage legally permissible.

The invention claimed is:
 1. A method, comprising, in combination:creating a core of a balloon by molding a core of a first material; andcoating an inner surface of the core and optionally an outer surface ofthe core with a second material, wherein the first material has adifferent elasticity than the second material, and wherein coatingfurther comprises: at least one of spraying, painting, and dipping theinner surface and optionally the outer surface to form a smooth surfacefinish having a roughness from approximately 0.1 microns toapproximately 0.7 micron.
 2. The method of claim 1, further comprisingfixing the balloon to a shaft of an intragastric device.
 3. The methodof claim 1, wherein the first material is more dimensional stable thanthe second material.
 4. The method of claim 1, wherein the firstmaterial has a greater elasticity than the second material.
 5. Themethod of claim 1, wherein the first material is primarily ofpolydimethylsiloxane.
 6. The method of claim 5, wherein the secondmaterial has higher acid resistance than the first material.
 7. Themethod of claim 5, wherein the second material is less permeable thanthe first material.
 8. The method of claim 5, wherein the secondmaterial is primarily of polydiphenylsiloxane.
 9. A product by theprocess of claim
 1. 10. A method, comprising, in combination: creating acore of a balloon by molding a core of a first material; and coating aninner surface of the core and optionally an outer surface of the corewith a second material to form a smooth surface finish having aroughness of approximately 0.1-0.7 micron, wherein the first materialhas a different elasticity than the second material.